Thermal Simulation of In-Space Additive Manufacturing
U.T. Kemmsies (TU Delft - Aerospace Engineering)
A. Cervone – Mentor (TU Delft - Astrodynamics & Space Missions)
Marcel Hermans – Mentor (TU Delft - Team Marcel Hermans)
Wei Ya – Mentor (Rotterdam Fieldlab Additive Manufacturing (RAMLAB))
Alessandra Menicucci – Graduation committee member (TU Delft - Space Systems Egineering)
K. Masania – Graduation committee member (TU Delft - Group Masania)
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Abstract
This thesis examines the thermal distribution and material behavior in in-space additive manufacturing (ISAM) using metal directed energy deposition (DED), addressing challenges of the orbital environment, including microgravity and vacuum. Experimental studies with a Scandium-modified Al-5183 alloy, conducted via Wire Are Additive Manufacturing, validated heat transfer coefficients and simulated ISAM thermal profiles. A finite element model, developed in Ansys Mechanical and calibrated with experimental data, accurately predicted overall thermal histories despite underestimating melt pool temperatures. Applied to orbital conditions, the model showed environmental healing effects were minimal for small components but significant for larger structures, supporting ISAM’s potential for space infrastructure. Material analysis revealed enhanced mechanical properties due to Scandium addition, with refined grains and Al3Sc precipitates. Integrating experiments, simulations, and characterization, this work advances ISAM thermal modeling, offering insights for future refinements in simulation accuracy and orbital testing.